Pyrolytic carbon black composite and method of making the same

ABSTRACT

A method of recovering carbon black includes the step of providing a carbonaceous source material containing carbon black. The carbonaceous source material is contacted with a sulfonation bath to produce a sulfonated material. The sulfonated material is pyrolyzed to produce a carbon black containing product comprising a glassy carbon matrix phase having carbon black dispersed therein. The pyrolysis can be conducted at a temperature from 1100° C. to 1490° C. A method of making a battery electrode and a lithium ion or sodium ion battery is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/945,239, filed on Jul. 18, 2013, the entirety of which ishereby incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

This invention was made with government support under contract No.DE-AC05-00OR22725 awarded by the U.S. Department of Energy. Thegovernment has certain rights in this invention.

FIELD OF THE INVENTION

This invention relates generally to producing materials containingcarbon particles, and more specifically to the production of materialscontaining carbon particles for battery electrodes.

BACKGROUND OF THE INVENTION

The widespread use of motor vehicles unavoidably results in largequantities of used tires. Globally, it is estimated that about 1.5billion waste tires are produced every year. In the past, used tireswere mostly disposed in landfills, which is not a sustainable solution.As more and more discoveries find that discarded tires pose seriousenvironmental and health threats to our society, proper recycling ofworn-out tires has become a critical issue. More recently other usagesof ground rubber tires have been found. In 2003 nearly 290 million scraptires were generated in the United States, and almost 80% of those wastetires were consumed in applications for fuel, as additives in civilengineering applications, and other uses. The recycled tires are mainlyconsumed as fuel, additives to plastics, rubbers, or civil engineeringapplications.

The tire rubber formulation contains significant quantities of carbonblack that is used as reinforcing fillers and abrasive resistance forrubber matrices. Typically, a tire consists of natural rubber, syntheticpolyisoprene, butadiene rubber, styrene-butadiene rubber, carbon blackand a fractional amount of additives. High structure carbon black madeof clusters of ˜10-100 nm size fundamental particles are used in tirerubber formulations to enhance mechanical properties of the product. Theregular direct pyrolysis process results in the production of about30-40 wt. % carbon black, depending on the pyrolysis conditions. Rubberparticles do not exist as a single fundamental particle; rather they arefused together during production of black to make aggregates of variousstructures. Such structures are retained in vulcanized rubber productssuch as pneumatic tires that contain dispersed phases of carbon black inrubber matrix.

The waste tire rubber is usually cryogenically pulverized into smallmicron-sized rubber particles. Cut rubber pieces are also ground inambient conditions to get powder buffing. Those powdered tire rubbersare usually used as fillers in various low-cost rubber or plasticproducts. Isolation of the carbon black from tire formulations was triedbut such products are not necessarily good reinforcing fillers for a newrubber formulation. Utilization of tire rubber materials for value-addedapplications would be very attractive not only for the recovery ofmaterials but also to control global pollution.

The search for suitable electrode materials for sodium-ion batteries hasbecome more urgent owing to the great need for large-scale energystorage. With the concerns of the limited global availability of lithiumresources and high cost, sodium-ion batteries (SIBs) are considered tobe an alternative to lithium-ion batteries (LIBs) for stationary gridenergy storage of electricity produced from renewable sources. Due toits high abundance, low cost, and suitable working chemical potential(−2.7 V vs. Standard Hydrogen Electrode), rechargeable sodium-ionbatteries are gradually attracting a lot of attention. Sodium sharesmany similar chemical properties with lithium because of its location inthe periodic table and the similarities of fundamental principles ofSIBs and LIBs. Thus far, several suitable cathode materials have beendeveloped for SIBs. However, the absence of good anode material hindersthe application of SIBs. Unlike the successful application of graphiteas anodes in LIBs, the electrochemical sodium insertion into graphite isproven to be not favorable. Theoretical calculations suggest that theinterlayer distance of graphite is too small to accommodate the largeNa⁺ ion, and a minimum interlayer distance of 0.37 nm is believed to begood for Na⁺ insertion. In this regard, a variety of carbon materialshave been investigated as anodes for SIBs, such as hard carbons, carbonnanotubes, reduced graphene oxides, and expanded graphite. Hard carbonis likely to be the most promising because of its stability, highcapacity, and easy scale-up. However, great amounts of the currentlystudied hard carbon are produced from sucrose, banana peels and dopamineamong others. Most of the precursors are relatively high cost or requirecomplex treatments, which prevent the application in many cost sensitivefields. A low-cost hard carbon anode material is desired for promotingthe development of SIBs for large-scale energy storage market.

SUMMARY OF THE INVENTION

A method of recovering carbon black comprises the steps of providing acarbonaceous source material containing carbon black, contacting thecarbonaceous source material with a sulfonation bath to produce asulfonated material, and pyrolyzing the sulfonated material to produce acarbon black containing product comprising a glassy carbon matrix phasehaving carbon black dispersed therein.

The sulfonation bath can be an oleum bath. The sulfonation bath cancomprise a sulfonation agent such as chlorosulfonic acid in 1,2dichloroethane solution. The sulfonation bath can comprise between0.1-65 wt. % SO₃. The sulfonation bath can comprise 2-30 wt. % SO₃. Thesulfonation bath can have a temperature of between −20° C. to 200° C.

The pyrolysis step can be conducted at a temperature that is greaterthan 200° C. The pyrolysis step can be conducted at a temperature thatis greater than 400° C. The pyrolysis step can be conducted at atemperature that is greater than 1000° C. The pyrolysis step can beconducted at a temperature that is between 200-1000° C. The duration ofthe pyrolysis step can be from 1 minute to 48 hours.

The method can further comprising the step of reducing the carbonaceoussource material to a powder prior to contacting the carbonaceous sourcematerial with the oleum bath. The powder or crumb rubber pieces can havean average maximum dimension of less than 100 nm to 10 cm.

The carbonaceous source material can comprise carbon reinforcedcomposites. The carbon reinforcing agent can be at least one selectedfrom the group consisting of carbon black, carbon particles,nanoparticles, mesoparticles and fibers. Mesoparticles are in the rangeof 100 nm to few microns in size with a pore diameter of 7-20 nm andhigh surface area. The carbonaceous source material can be a wastematerial, for example, particularly recyclable material. The wastematerial can be rubber tires, for example.

The average pore size of the carbon black product can be less than 8 nm.The average pore size of the carbon black product can be between 2 and120 nm. The isolated carbon can be further surface activated and thedensity of average pore size of the carbon black product between 1 and20 nm can be increased.

The carbon black containing product can have a specific surface area ofless than 3000 m²/g. The carbon black containing product can have aspecific surface area of less than 2000 m²/g, or less than 1000 m²/g.The carbon black containing product can have a specific surface area ofless than 100 m²/g. The carbon black containing product can have aspecific surface area of less than 10 m²/g.

The pyrolyzing step can occur after the contacting step. The pyrolyzingstep can occur before the contacting step.

A method of making a battery electrode comprising carbon black caninclude the steps of providing a carbonaceous source material containingcarbon black, contacting the carbonaceous source material with an oleumbath to produce a sulfonated material, pyrolyzing the sulfonatedmaterial to produce a carbon black product comprising a glassy carbonmatrix phase having carbon black dispersed therein, and forming abattery electrode from the carbon black containing product. The batteryelectrode can be an anode. The battery can be a lithium ion or a sodiumion battery. The battery electrode can be two active electrodes. Thebattery can be a supercapacitor.

A method of recovering carbon black includes the step of providing acarbonaceous source material containing carbon black. The carbonaceoussource material is contacted with a sulfonation bath to produce asulfonated material. The sulfonated material is pyrolyzed at atemperature of from 1100 to 1490° C. to produce a layered carbon blackcontaining product comprising a glassy carbon matrix phase having carbonblack dispersed therein. The layered carbon black containing product hasan interlayer spacing of from 4 to 5 angstroms (0.4 to 0.5 nm).

A method of making a battery electrode comprising carbon black caninclude the step of providing a carbonaceous source material containingcarbon black, contacting the carbonaceous source material with an oleumbath to produce a sulfonated material, and pyrolyzing the sulfonatedmaterial at a temperature of from 1100 to 1490° C. to produce a layeredcarbon black product comprising a glassy carbon matrix phase havingcarbon black dispersed therein. The layered carbon black containingproduct can have an interlayer spacing of from 4 to 5 angstroms (0.4 to0.5 nm). A battery electrode can then be formed from the carbon blackcontaining product.

A battery can include an anode comprising layered carbon blackcontaining product obtained by providing a carbonaceous source materialcontaining carbon black, contacting the carbonaceous source materialwith an oleum bath to produce a sulfonated material, pyrolyzing thesulfonated material at a temperature of from 1100 to 1490° C. to producethe layered carbon black product comprising a glassy carbon matrix phasehaving carbon black dispersed therein. The layered carbon blackcontaining product having an interlayer spacing of from 4 to 5 angstroms(0.4-0.5 nm). A cathode is provided and an electrolyte is disposedbetween the anode and the cathode.

BRIEF DESCRIPTION OF THE DRAWINGS

There are shown in the drawings embodiments that are presently preferredit being understood that the invention is not limited to thearrangements and instrumentalities shown, wherein:

FIG. 1 is a schematic diagram of a method for recovering carbon black inmodified form from recycled tire rubber.

FIG. 2 is thermogravimetric analysis (TGA) thermograms of precursors forSample #1 (control tire rubber) and Sample #2 (sulfonated tire rubber).

FIG. 3A is cumulative pore volume data based on BETadsorption-desorption data analysis of carbons from Sample #1 (controltire rubber-derived carbon) and Sample #2 (carbon from sulfonated tirerubber powder). FIG. 3B is differential pore volume in both carbons (inmagnified scale) at smaller pore widths.

FIG. 4 is cycling performance of the control tire rubber-derived carbon(Sample #1) anode at 0.1 C.

FIG. 5 is the 1st and 2nd charge-discharge curves of the control tirerubber (Sample #1)-derived carbon anode at 0.1 C.

FIG. 6 is rate performance of the control tire rubber (Sample#1)-derived carbon anode.

FIG. 7 is cycling performance of the sulfonated tire rubber (Sample#2)-derived carbon anode at 0.1 C.

FIG. 8 is 1st and 2nd charge-discharge curves of the sulfonated tirerubber (Sample #2)-derived carbon anode at 0.1 C.

FIG. 9 is the rate performance of the half-cell made from sulfonatedtire rubber (Sample #2)-derived carbon.

FIGS. 10A, 10B, and 10C are TEM images of control tire rubber (Sample#1)-derived carbon. FIG. 10D is a Selected Area Electron Diffractionpattern.

FIGS. 11A and 11B are TEM images of sulfonated rubber tire (Sample#2)-derived carbon. FIG. 11C is a Selected Area Electron Diffractionpattern.

FIG. 12A is X-ray diffraction patterns and FIG. 12B Raman spectra oftire-derived carbons obtained by pyrolyzing at different temperatures.

FIGS. 13A and 13B are X-ray photoemission spectroscopy (XPS) ofsulfonated tire rubber-derived carbons. FIG. 13A shows C1s scans andFIG. 13B shows S2p scans. The insert in FIG. 13A shows the expandedbinding energy plots.

FIGS. 14A, 14B, 14C and 14D demonstrate cycling performances of (14A)TC1100, (14B) TC1400, and (14C) TC1600, and (14D) a comparison ofdischarge and charge curves of all the carbons.

FIG. 15 is a comparison of the discharge and charge curves of TC1600 at25th, 50th, 75th, and 100th cycles.

FIG. 16 is the long-cycle stability test of TC1100 at a current densityof 20 mA g⁻¹.

DETAILED DESCRIPTION OF THE INVENTION

A method of recovering carbon black as shown in FIG. 1 includes the stepof providing a carbonaceous source material containing carbon black. Thecarbonaceous source material is soaked in a sulfonation bath to producea sulfonated material. The sulfonated material is pyrolyzed to produce acarbon black containing product comprising a glassy carbon matrix phasehaving carbon black dispersed therein.

The sulfonation bath can comprise any reactant composition capable ofsulfonating rubber. It is also capable of sulfonating vulcanizedparticulate rubbers containing carbon black or carbon particles orcarbon fiber or carbon nanomaterials. In one aspect the sulfonation bathcan be an oleum bath. The oleum bath can comprise up to 65 wt. % SO₃ inconcentrated sulfuric acid. Very high SO₃ content in oleum bath causessolidification of reactant mix and therefore, may not be useful forprocessing. The sulfonation bath can be a sulfuric acid (H₂SO₄)solution. The concentration of sulfuric acid in the oleum bath can bebetween 10 and 100 wt. %. The sulfonation bath can comprise othersulfonation agents such as chlorosulfonic acid in 1,2 dichloroethanesolution, organic solvents (such as 1,2 dicholoroethane) containing SO₃gas, or equimolar mixture of acetic anhydride concentrated sulfuric acidthat yields acetyl sulfate. Acetyl sulfate assists in electrophilicsulfonation of aromatic ring in styrene containing rubbers but SO₃ canaid free radical sulfonation of aliphatic segments. Thus, thesulfonation bath can comprise a liquid, a gas, or a liquid and a gas.The sulfonation bath can comprise between 0.1-65 wt. % SO₃ in liquidmedium that can be concentrated sulfuric acid or organic solvents. Thesulfonation bath can comprise any minimum percentage and maximumpercentage within this range, such as 5-20, 2-18, 2-30, or 0.1-2 wt. %SO₃.

The sulfonation bath can have a temperature of between −20 to 200° C.

The pyrolysis step can be conducted at a temperature that is greaterthan 400° C. The pyrolysis step can be conducted at a temperature thatis greater than 1000° C. The pyrolysis step can be conducted at atemperature that is between 200-1000° C. The duration of the pyrolysisstep can be from 1 minute to 12 hours or more. The conditions of thepyrolysis step such as temperature and duration can be selecteddepending on process conditions including the particular carbonaceoussource material that is being pyrolyzed.

The pyrolysis step of high carbon content hydrocarbon polymer compositescan also be maintained at the desulfonation temperature range whensulfur containing volatiles comes out of the material leavingunsaturated hydrocarbon with high carbon content.

The carbon content in pyrolyzed carbon materials can be higher than 80wt. %.

The method can include the steps of reducing the carbonaceous sourcematerial to a powder prior to contacting the carbonaceous sourcematerial with the oleum bath. The powder can be formed by any suitablemethod such as grinding, milling, cutting, and cryogenic pulverization.The powder so formed can have an average maximum dimension of less than100 nm to 10 cm. Also, crumb rubber with a size of less than 10 cm widecan also be used without grinding. Metal particles such as Ni, stainlesssteel, Iron, and oxides such as ZnO, SiO₂ and others present along withcarbonaceous source material may also dissolve in the oleum bath andyield carbon powder with no metals and/or oxides or up to ppm levels ofmetals. The presence of Ca comes from caolin or talc filler in rubbercompounds and can form insoluble sulfates by reaction with sulfonatingagents such as, for example, sulfuric acid. To avoid such impurities, ifrequired, the tire rubbers can be washed with aqueous hydrochloric acid,nitric acid, or an acidic salt (for example ammonium chloride) solutionprior to sulfonation.

The carbonaceous source material can be any suitable carbon blackcontaining source material. One such source material comprises carbonblack loaded plastics, scrap electronic casing containing carbon blackloaded plastics that serve as electromagnetic shielding material,polymeric carbon nanocomposites containing carbon particles, and carbonfiber reinforced composites. The carbonaceous source material can be awaste material, such as scrap vulcanized rubber tires or recycledvulcanized rubbers from other sources.

The product of the invention is a carbon black containing productcomprising a glassy carbon matrix phase having carbon black dispersedtherein. The carbon black containing carbonaceous product is porous witha multi-modal pore size distribution with some pore width r, where 8nm<r>120 nm and some pore width less than 8 nm but greater than 2 nm.The average pore size of the carbon black containing product can bebetween 2 and 120 nm. The carbon black containing product can have aBrunauer-Emmett-Teller (BET) specific surface area of less than 1000m²/g depending on the continuity of carbon matrix. The specific surfacearea in composite can be less than 100 m²/g.

The BET specific surface area in the carbon particle containing carbonmatrix products can further be modified by deploying a surfaceactivation process. Surface activation process is well known in art thatproduces activated carbon. Activated carbon can be synthesized frompyrolyzed carbon residues by activating it in steam or CO₂ at elevatedtemperature ranging from 200 to 1000° C. that results partially burntout carbon residue with higher porosity. The added porosity by surfaceactivation is usually microporosity with pore widths less than 50 nm.Activation of carbon can also be achieved by treating it with alkalifollowed by heat treatment in the presence of water vapors.

A battery electrode can be formed from the carbon black containingproduct. This electrode can be an anode for lithium-ion or sodium-ionbatteries.

A method of making a battery electrode comprising carbon black caninclude the steps of providing a carbonaceous source material containingcarbon black, contacting the carbonaceous source material with asulfonation bath to produce a sulfonated material, pyrolyzing thesulfonated material to produce a carbon black containing productcomprising a glassy carbon matrix phase having carbon black dispersedtherein; and forming a battery electrode from the carbon blackcontaining product. The electrode can be an anode. The battery can beformed by suitable techniques. The battery can be a lithium (Li) ionbattery, and/or a sodium (Na) ion battery.

Carbon black was recovered from powdered tire rubber by two methods: (1)simple pyrolysis of powder rubber at 1000° C. (nitrogen atmosphere) thatyields 30-40% carbon (control rubber tire-derived carbon, Sample #1) and(2) digestion of rubber powders in a hot oleum bath (18-24% SO₃) toyield sulfonated rubber powder that was then filtered, washed andcompressed to make a solid cake followed by pyrolysis in an inertatmosphere (sulfonated rubber tire-derived carbon, Sample #2). Sample 2produced a carbon monolith with a little higher yield (2-5% increase incarbon yield compared to the control rubber powder; Sample 1) whereasSample 1 produced fluffy (low bulk density) powder of carbon black. Theisolated carbon material (from either sample) was used to test theirelectrochemical performance as an active anode material in Li-ionbattery.

Carbon black was also isolated from ground tire rubber by conventionalpyrolysis (400-1000° C. in inert atmosphere) followed by treatment ofthe char with oleum bath and subsequent heat treatment of washed/driedcharred residue in inert environment. The oleum bath can have aconcentration of 0.1-30 wt. % SO₃. Since the material was charred beforetreatment in sulfonation bath it does not require very high temperaturetreatment in second carbonization step. The second heat treatment can beabove 200° C.; however, higher temperature gives higher rigidity orgraphitic order in the derived carbon.

Example 1

Fire rubber powder of 80-120 urn size range consisting of polymermixture of natural rubber, butadiene rubber, and styrene-butadienerubber (45%), carbon black (33%), inorganic filler and vulcanizationactivator (10%) and residual extractable and volatile materials withspecific gravity of 1.15 g/cc was used for the pyrolytic recovery ofcarbon black. The powder rubber sample was heated in a tubular furnaceunder nitrogen atmosphere at 1000° C. The temperature of the furnace wasraised from room temperature to 1000° C. by heating it at 10° C./min andwhen it reached at 1000° C. it was held at that temperature for 15minutes. The furnace was cooled to room temperature and the carbonresidue was collected. The sample is termed as control carbon (Sample#1). The carbon black yield was 33%.

Example 2

Tire rubber powder of 80-120 μm size range consisting of polymer mixtureof natural rubber, butadiene rubber, and styrene-butadiene rubber (45%),carbon black (33%), inorganic filler and vulcanization activator (10%)and residual extractable and volatile materials with specific gravity of1.15 g/cc was used for a chemical pretreatment prior to pyrolysis. Thetire rubber powder was treated with fuming sulfuric acid containing 20wt. % free SO₃ gas at 70° C. for 12 h. The tire rubber slurry wasfiltered on a Buchner funnel with sintered glass disc (fritted glassfunnel) using an aspirator followed by washing with distilled water. Thewashed sulfonated tire rubber cake was then dried at 80° C. for 1 hfollowed by pyrolysis in tubular furnace under nitrogen atmosphere at1000° C. The furnace temperature was reached to 1000° C. by heating thefurnace from room temperature at 10° C./min and allowing a soak time of15 minute at 1000° C. The furnace was allowed to cool to roomtemperature and the environment was maintained under nitrogen before thesample was taken out.

Example 3

Tire rubber powder of 80-120 μm size range consisting of polymer mixtureof natural rubber, butadiene rubber, and styrene-butadiene rubber (45%),carbon black (33%), inorganic filler and vulcanization activator (10%)and residual extractable and volatile materials with specific gravity of1.15 g/cc was used for a chemical pretreatment prior to pyrolysis. Thetire rubber powder was treated with fuming sulfuric acid containing 20wt. % free SO₃ gas at 70° C. for 12 h. The tire rubber slurry wasfiltered on a Buchner funnel with sintered glass disc (fritted glassfunnel) using an aspirator followed by washing with distilled water. Thewashed sulfonated tire rubber cake was then pressed between Teflonsheets under a hot plate inside a compression mold at 110° C. to get ridof moisture and to obtain a thick (2 mm) molded sheet followed bypyrolysis in tubular furnace under nitrogen atmosphere at 1000° C. Thefurnace temperature reached 1000° C. by heating the furnace from roomtemperature at 10° C./min and allowing a soak time of 15 minutes at1000° C. The furnace was allowed to cool to room temperature and theenvironment was maintained under nitrogen before the monolith carbonsample was taken out. The sample is termed as sulfonatedtire-rubber-derived carbon (Sample #2). The yield of carbon based on asreceived material (non-sulfonated rubber) was 38%.

Example 4

The tire rubber of 0.5 mm size consisting of polymer mixture of naturalrubber, butadiene rubber, and styrene-butadiene rubber (42%), carbonblack (33%), inorganic filler and vulcanization activator (11%) andresidual extractable and volatile materials with specific gravity of1.14 g/cc was used for a chemical pretreatment prior to pyrolysis. Thetire rubber was treated with fuming sulfuric acid containing 30 wt. %free SO₃ gas at 40° C. for 48 h. The tire rubber slurry was filtered ona fritted glass funnel using an aspirator followed by washing withdistilled water. The washed sulfonated tire rubber cake was then driedat 80° C. for 1 h followed by pyrolysis in tubular furnace undernitrogen atmosphere at 600° C. The furnace temperature reached 600° C.by heating the furnace from room temperature at 10° C./min and allowinga soak time of 60 minutes at 600° C. The furnace was allowed to cool toroom temperature and the environment was maintained under nitrogenbefore the sample was taken out. The yield of carbon based on asreceived material (non-sulfonated rubber) was 40%.

Example 5

Tire rubber powder of 80-120 μm size range consisting of polymer mixtureof natural rubber, butadiene rubber, and styrene-butadiene rubber (45%),carbon black (33%), inorganic filler and vulcanization activator (10%)and residual extractable and volatile materials with specific gravity of1.15 g/cc was used for a chemical pretreatment prior to pyrolysis. Thetire rubber powder was treated with concentrated sulfuric acid (98%H₂SO₄) at 100° C. for 24 h. The tire rubber slurry was filtered on afritted glass funnel using an aspirator followed by washing withdistilled water. Washed sulfonated tire rubber cake was then dried at80° C. for 1 h followed by pyrolysis in tubular furnace under nitrogenatmosphere at 600° C. The furnace temperature reached 600° C. by heatingthe furnace from room temperature at 10° C./min and allowing a soak timeof 60 minute at 600° C. The furnace was allowed to cool to roomtemperature and the environment was maintained under nitrogen before thesample was taken out. The yield of carbon based on as received material(non-sulfonated rubber) was 37%.

Example 6

Carbon black was isolated from ground tire rubber by conventionalpyrolysis at 600° C. in inert atmosphere. The isolated porous carbon orthe char was treated in oleum bath at 70° C. for 12 h; the oleum had 20wt. % SO₃ in concentrated sulfuric acid. The slurry of carbonaceous masswas washed, dried, and subsequent heat treated in inert environment (N₂)at 1000° C. The heating of furnace was conducted at 12° C./min from roomtemperature to 1000° C. and maintained 1000° C. for 15 minutes before itwas cooled to room temperature.

In all the examples, pyrolysis can also be done in Argon or other inertatmosphere such as Helium instead of nitrogen atmosphere.

Results

The schematic of the recovery of pyrolytic carbon black materials (bothin unmodified and modified forms), from the recycled tires, is shown inFIG. 1. The schematic shows that these are used as low-cost anodes inlithium-ion batteries.

The TGA data of the Samples 1-2 are shown in FIG. 2. The first weightloss in sample 2 around 150° C. is the desulfonation step that shiftsthe pyrolysis temperature of rubber to slightly higher temperature. Therelative char yield in desulfonated material, compared to control tirerubber (Sample #1), is slightly higher.

The Brunauer-Emmett-Teller (BET) surface area analysis of the recoveredcarbon from Samples 1 and 2 are displayed in FIG. 3. In control Sample#1 the pore sizes are in the range of 8-13 nm (80-130 Å) and it does notshow any pore width smaller than 8 nm. However the sulfonation treatmentprior to pyrolysis allows formation very small volume fraction of poreswith width of 3-4 nm. Without wishing to be limited, it is believed thatthese pores are detected due to the thin carbon films created on thecarbon black particles by the pyrolyzing char-forming rubber (sulfonatedrubber). When the rubber is not sulfonated it does not yield detectablechar. Further, sulfonation creates hard carbon with low pore volume.Data analysis shows that sulfonated tire rubber yields carbon with 64m²/g specific surface area; whereas that of the control carbon (fluffycarbon from Sample #1) is 96 m²/g.

Electrochemical studies were done by preparing CR2032 coin cells. Thecoin half cells were assembled in an argon-filled glove box usingrecycled carbon (Samples #1 and #2), as the working electrode andmetallic lithium foil as the counter electrode. The anode was preparedby casting slurry of 80% active recycled carbon material, 5 wt. % superconducting carbon, and 15 wt. % polyvinylidene difluoride (PVDF) binderin n-methyl-2-pyrrolidone (NMP) solvent on copper foil. The maincharacteristics of conducting carbon are high purity, long structure andmoderate surface area. It is also possible use up to 95% active recycledcarbon material and down to 5 wt. % polyvinylidene difluoride (PVDF)binder in n-methyl-2-pyrrolidone (NMP) solvent on copper foil. Theelectrolyte for Li-ion batteries consisted of a solution of 1 M LiPF₆ inethylene carbonate (EC)/dimethyl carbonate (DMC)/diethyl carbonate (DEC)(1:1:1 by volume). Galvanostatic charge/discharge cycling between thevoltages of 0-3.0 V was performed at room temperature under differentrates using an Arbin potentiostat/galvanostat multichannel system. Theuse of active super carbon in the electrode slurry composition can beminimized and finally eliminated if the isolated carbons (Sample #1 or2) are activated by conventional method for activated carbon synthesis,followed by high temperature treatment at temperature T, where 3000°C.<T>1000° C., that increases electrical conductivity significantly.Steam or CO₂ activation increases porosity and active surface area inthe produced or recovered carbon materials.

FIG. 4 shows the cycling performance of the control tire rubber (Sample#1)-derived carbon at 0.1 C or C/10 (where 1 C corresponds to onecharge-discharge cycle in an hour). FIG. 5 shows the galvanostaticdischarge/charge curves of the same anodes (control tire rubber-derivedcarbon) between 0 and 3 V at a rate of 0.1 C. According to FIGS. 4 and5, Sample #1-derived carbon exhibited an initial capacity of ˜900 mAh/gat the first discharge, but the reversible capacity of only ˜500 mAh/gwas attained, which led to much lower initial coulombic efficiency of45%. Then the capacity decreased to ˜200 mAh/g and the coulombicefficiency increased slowly to 99% after 45 cycles. FIG. 6 shows therate performance of the control tire rubber (Sample #1)-derived carbonanodes. It clearly shows a rate performance with ˜100 mAh/g at 1 C, only˜40 mAh/g at 5 C, which are much lower than the sulfonated tire rubber(Sample #2)-derived carbon.

FIG. 7 shows the cycling performance of the half-cell made fromsulfonated tire rubber-derived carbon (Sample #2) materials. A half-cellmade by use of Sample #2 exhibited a reversible capacity of ˜400 mAh/gafter 100 cycles with coulombic efficiency of almost 100%. This resultis comparable to the theoretical capacity of 362 mAh/g for commercialcarbon anodes. FIG. 8 shows the galvanostatic discharge/charge curves ofthe anodes made from sulfonated tire rubber-derived carbon between 0 and3 V at a rate of 0.1 C. During the first discharge, the voltagepseudoplateau near 0 V contributes to a large irreversible capacity. Thefirst discharge capacity is around 500 mAh/g, and a reversible chargecapacity around 400 mAh/g, leading to an irreversible capacity of 100mAh/g. However, both second discharge capacity and reversible chargecapacity is around 400 mAh/g. The reversible capacity was maintained to100 cycles. FIG. 9 shows the rate performance of the sulfonated tirerubber-derived carbon (Sample #2) anodes. It clearly shows a good rateperformance with ˜270 mAh/g at 1 C, 160 mAh/g at 5 C, and over 50 mAh/gat 10 C. Results obtained from Sample #1 were compared with Sample #2.Based on these results, electrochemical performances of carbon fromSample #2 are much better than those from Sample #1.

TEM images of carbon from Samples #1 and #2 are reported in FIGS. 10 and11. Sample #1 (FIG. 10) has the morphology of spherical nanoparticleswith an irregular cluster shape. Selected Area Electron Diffractionpattern indicates the presence of completely amorphous carbon materials.Sample #2-derived carbon (FIG. 11) has the morphology of 1D (onedimensional) nanostructure. It formed a monolith hard carbon and whenthat was ground it formed fibriler or oriented structure. Selected AreaElectron Diffraction pattern indicates the presence of both crystallineand amorphous carbon materials.

These results demonstrate that recycled carbon materials with propertreatment have been used successfully to develop a novel, low-cost,rechargeable anodes for lithium ion batteries. Recovered hard carbonswhen treated properly (CO₂ or steam activation) after or duringcarbonization can yield very high surface area. It is expected thatsample #1 being amorphous in nature can be activated easily with higherburn out rate than that of sample #2 under identical conditions. Anexemplary activation condition was exposure of the carbon samples at700° C. under constant flow of CO₂ for 2 hours. Those activated carbonswould be useful for supercapacitors, in addition to Li-ion batteries,Na-ion batteries, and other energy storage devices as well. Theactivation can also be done by treating sulfonated precursor to a hightemperature where desulfonating gases cause surface activation. Sulfuricacid treated graphites particles are conventionally used to makeexfoliated graphene oxide material [Hummers W S; Offeman R E. J. Am.Chem. Soc. 1985, 80(6), 1339].

Relatively low packing density and higher operating voltage are amongthe main obstacles for hard carbons to be used as an anode in LIBs.These obstacles are not as significant for SIB applications sincesodium-ion batteries are mostly targeted for stationary energy storageand also the Na/Na⁺ couple operates 0.34 V higher than Li/Li⁺ couple. Ahigher temperature of pyrolysis leads to a larger sodium storagecapacity, which behaves opposite to that of some hard carbons producedin the same temperature range and used against lithium. Unlike most hardcarbon voltage profiles in LIBs, the plateau capacity at low-potentialregion increases significantly as the pyrolysis temperature increases,which is beneficial to increase the cell voltage and energy density.

A method of recovering carbon black includes the step of providing acarbonaceous source material containing carbon black. The carbonaceoussource material is contacted with a sulfonation bath to produce asulfonated material. The sulfonated material is pyrolyzed at atemperature of from 1100 to 1490° C. to produce a layered carbon blackcontaining product comprising a glassy carbon matrix phase having carbonblack dispersed therein. The layered carbon black containing product hasan interlayer spacing of from 4 to 5 angstroms (0.4-0.5 nm).

The sulfonation bath can be an oleum bath. The sulfonation bath caninclude a sulfonation agent which can be chlorosulfonic acid in 1,2dichloroethane solution. The sulfonation bath can include between 0.1-65wt. % SO₃. The sulfonation bath can include 2-30 wt. % SO₃. Thesulfonation bath can have a temperature of between −20° C. to 200° C.

The pyrolysis step can be conducted at any suitable temperature or rangeof temperatures from 1100° C. to 1490° C. The pyrolysis step can beconducted at a temperature that is greater than 1200° C. The pyrolysisstep can be conducted at a temperature that is greater than 1300° C. Thepyrolysis step can be conducted at a temperature from 1200-1400° C. Thepyrolysis step can be conducted at a temperature from 1250-1350° C. Thepyrolysis step is conducted at a temperature from 1100-1400° C. Thepyrolysis step can be from 1 minute to 12 hours.

The method can further include the steps of reducing the carbonaceoussource material to a powder or shredded tire pieces prior to contactingthe carbonaceous source material with the oleum bath. The powder and/orcrumb rubber pieces can have an average maximum dimension of less than100 nm to 10 cm.

The carbonaceous source material can include carbon reinforcedcomposites. The carbon reinforcing agent can be least one selected fromthe group consisting of carbon black, carbon particles, nanoparticles,mesoparticles and fibers. The carbonaceous source material can be awaste material. The waste material can be rubber tires.

The average pore size of the carbon black product can be less than 8 nm.The average pore size of the carbon black product can be between 2 and120 nm. The isolated carbon can be further surface activated and thedensity of average pore size of the carbon black product between 1 and20 nm is increased.

The carbon black containing product can have a specific surface area ofless than 2000 m²/g. The carbon black containing product can have aspecific surface area of less than 1000 m²/g. The carbon blackcontaining product can have a specific surface area of less than 100m²/g.

The pyrolyzing step can occur after the contacting step. The pyrolyzingstep can occur before the contacting step.

A method of making a battery electrode comprising carbon black caninclude the step of providing a carbonaceous source material containingcarbon black, contacting the carbonaceous source material with an oleumbath to produce a sulfonated material, and pyrolyzing the sulfonatedmaterial at a temperature of from 1100 to 1490° C. to produce a layeredcarbon black product comprising a glassy carbon matrix phase havingcarbon black dispersed therein. The layered carbon black containingproduct can have an interlayer spacing of from 4 to 5 angstroms (0.4-0.5nm). A battery electrode can then be formed from the carbon blackcontaining product.

The battery electrode can be an anode. The battery can be a lithium ionbattery or a sodium ion battery. The battery can have any suitableconstruction.

A battery can include an anode comprising layered carbon blackcontaining product obtained by providing a carbonaceous source materialcontaining carbon black, contacting the carbonaceous source materialwith an oleum bath to produce a sulfonated material, pyrolyzing thesulfonated material at a temperature of from 1100 to 1490° C. to producethe layered carbon black product comprising a glassy carbon matrix phasehaving carbon black dispersed therein. The layered carbon blackcontaining product having an interlayer spacing of from 4 to 5 angstroms(0.4-0.5 nm). A cathode is provided and an electrolyte is disposedbetween the anode and the cathode. The layered carbon black containingproduct can have a surface atomic composition that is greater than 92%carbon.

Pulverized tire rubber powder in the size range of 80-120 μm wasobtained from Lehigh Technologies, Inc., Georgia. The tire rubberpowders were soaked in a concentrated sulfuric acid bath (kept at 110°C. for overnight) to yield the sulfonated tire rubber that was thenwashed and filtered off. The washed sulfonated tire rubber was thenpyrolyzed at 1100° C., 1400° C., and 1600° C., respectively, in a tubefurnace under flowing nitrogen gas, and they are hereafter designated asTC1100, TC1400, and TC1600.

The X-ray diffraction (XRD) data were collected with a PANalyticalEmpyrean diffractometer equipped with Cu Kα radiation (λ=1.5406 Å).Nitrogen adsorption desorption isotherms were obtained with aQuantachrome NovaWin1000 surface area & porosity analyzer at 77.4° K.The specific surface area was determined by the Brunauer-Emmett-Teller(BET) method. The pore size distribution was obtained by theBarret-Joyner-Halenda (BJH) method. Raman spectra were collected with aHoriba LabRam HR using an excitation wavelength of 473 nm, a 600 gr/mmgrating and an 800 mm monochromator. A Zeiss Merlin VP scanning electronmicroscope (SEM) operated at 3 kV was used to characterize the surfacemorphologies of the samples. Interlayer distances of the carbons weredetermined by a Hitachi HD-2300A scanning transmission electronmicroscope (STEM) with a field emission source operated at 200 kV inbright-field imaging mode at a 2.1 Å resolution. XPS data were collectedwith a Thermo-Fisher K-alpha XPS with a monochromatic Al-K_(alpha), a1486.6 eV source, 400 μm spot, and an argon ion flood gun.

Electrochemical properties were characterized with half cells against asodium-metal electrode. The working electrode was prepared by spreadingthe mixed slurry consisting of the active material, conductive carbonC45 and PVDF binder in N-methyl-2-pyrrolidone (NMP) solvent at a weightratio of 80:10:10. The resulting slurry was then cast onto a copper foilcurrent collector and transferred to a vacuum oven for drying at 120° C.overnight. The typical loading amount of active material was 2 to 2.5 mgcm⁻². The electrolyte was a solution of 1 M NaClO₄ in ethylene carbonate(EC) and diethyl carbonate (DEC) (1:1 in vol). Coin cells (CR2032)consisting of the tire-derived carbon electrode, glass fiber, a sodiummetal counter electrode and electrolyte were assembled in an Ar-filledglove box. Galvanostatic charge/discharge was carried out on a LandCT2001 battery test system (Wuhan, China) over a voltage range of 0-3 Vat current density of 20 mA g⁻¹ at room temperature. The sodiatedelectrodes were disassembled in an Ar-filled glovebox and placed in anair-sensitive sample holder for further characterizations. The ex situXRD analysis was performed on a Rigaku Miniflex600 diffractometer withCu Kα radiation.

As shown in FIG. 12A, XRD collected on bulk materials indicate that thetire-derived carbons pyrolyzed at different temperatures are mainlycomposed of poorly crystalline carbonaceous material. The broad peaknear 28-26.6° suggests lack of significant order in the bulk of thecarbon materials and this peak is related to the (002) plane. The Rvalue for TC1100, TC1400, and TC1600 are 1.58, 2.27 and 2.67,respectively. Here, R is defined as the peak height divided by thebackground height at the position of the peak. The value of R can beused to estimate the fraction of graphene sheets, which increases as theproportion of the graphene layers with parallel neighbors increases.TC1600 shows the largest graphene fraction by the comparing three Rvalues. Raman spectra obtained on tailored carbons are shown in FIG.12B. The ID/IG ratio for TC1100, TC1400, and TC16000 increases from 0.85to 0.96 to 0.99. Such a trend has also been reported for hard carbonmaterial obtained from other precursors. The ID/IG ratio changesdifferently in a three-stage model of increasing disorder. The G peak isdue to the bond stretching of all pairs of sp2 atoms in both rings andchains. The D peak is due to the breathing modes of sp2 atoms in therings. The ratio of ID/IG is proportional to the number of aromaticrings. The increased relationship in the ID/IG ratio and G band positionfor the tire-derived carbons shows that more sp2 amorphous carbon turnsinto nanocrystalline graphite at higher temperatures. This tendency canalso be concluded and confirmed by the R values.

From the nitrogen adsorption-desorption plots for the sulfonated tirerubber-derived carbons, the BET surface areas for TC1100, TC1400, andTC1600 are determined to be 189, 210 and 148 m² g⁻¹, respectively. Thepore volume distribution shows a relatively wide pore size distributionwith prominent microporosity with a pore width of less than 2 nm and anoticeable volume fraction of pore widths in the range of 6-8 nm. Thedominant microporosity could be attributed to the fact that the sulfuricacid pretreated tire powder produces SO₂ and steam which yieldsactivated tire-derived carbon. The SEM images of different temperaturetreated tire-derived carbons exhibit similar surface porosityproperties. SEM images of TC1400 show a large number of macro- andmeso-pores are visible on the sample surface. From the high resolutionscanning transmission electron microscopy (STEM) images of sulfonatedtire-derived carbon treated at 1100° C., 1400° C. and 1600° C., theinterlayer distances for crystalline areas were determined to be 4.7 Å,4.5 Å, and 4.0 Å for TC1100, TC1400 and TC1600, respectively. Thesevalues are larger than the required distance (0.37 nm) for sodiumintercalation and follow the general trend that the carbon interlayerdistance decreases with increasing pyrolysis temperatures. The selectedarea electron diffraction (SAED) patterns of the three temperaturetreated carbon indicate that the amorphous phase dominates. It is alsoclear that the TC1600 carbon has more crystalline phases compared to thelower temperature pyrolyzed carbon.

X-ray photoemission spectroscopy (XPS) data on the tire-derived carbonsare shown in FIG. 13. The C1s spectrum in FIG. 13A for the samples showsa sharp peck at 284.8 eV, which is due to the sp² configuration. Thefitting results for C1s spectrum also show small amounts of C—O, C═O,and aromatic C functional groups on the surface. The small peak ataround 291 eV could be related to the presence of aromatic rings in thematerials and as shown in the inset that its relative intensityincreases with the pyrolysis temperatures. This result also confirms theconclusion by Raman spectra that more aromatic rings are present in thehigher temperature samples. FIG. 13B shows the S2p scans of the samples.The doublets at about 164 eV are related to the thiol group and the peakat 169 eV is due to the sulfate group. It is shown that as thetemperature increases, sulfate groups are removed from the samples. TheXPS elemental analysis for the samples is shown in Table 1. Theimpurities of Si and Fe could be due to the additives or impuritiespresent in the tire powders. It is clear that the purity improves as thepyrolysis temperature increases since more functional groups areeliminated at higher temperatures.

TABLE 1 XPS surface concentration (in atomic percentages) of TC1100,TC1400 and TC1600. XPS Elemental Analysis (% Surface Atomic Composition)Sample Si S C O Fe TC1100 1.5 1.1 82.1 14.8 1.52 TC1400 0.9 0.6 92.6 4.4— TC1600 0.5 0.5 95.5 3.6 —

The electrochemical performances of tire-derived carbons were evaluatedin sodium half cells. FIG. 14 A-C show the cycling stability of thethree samples tested under a current density of 20 mA g⁻¹. TC1100provides an initial capacity of 520 mAh g⁻¹ for discharge and 250 mAhg⁻¹ during charge, which corresponds to only 48% coulombic efficiencyfor the first cycle in FIG. 14A. The large irreversible capacity losscould be associated with the high surface area of the carbon materialand the reduction of carbon surface functional groups followed byelectrolyte decomposition and formation of solid electrolyte interphase(SEI). Surface coating techniques could be used in the future to reducethe surface area and to improve the efficiency. After the 10th cycle,the coulombic efficiency increases to above 99% and the capacity becomesstabilized. The capacity at the 100th cycle was 179.4. Compared toTC1100, the cycling results for TC1400 and TC1600 in FIG. 14B and FIG.14C show improvements in first cycle efficiency and capacity. TC1400exhibits 57% first cycle efficiency and a capacity of 185 mAh g⁻¹ after100 cycles whereas TC1600 shows further enhancement of the first cycleefficiency to 66% and a capacity of 203 mAh g⁻¹ at 100th cycle. Theimproved cycling performance may be related to the reduced number ofsurface functional groups and also reduced amount of defects in thecarbon after the higher temperature treatment.

FIG. 14D presents the electrochemical voltage profiles when sodium isintercalated and deintercalated from the various tire-derived carbons.It can be seen that the TC1100 voltage profile mostly consists of thesloping region during cycling. However, both the TC1400 and TC1600charge and discharge curves can be divided into two regions, a slopingvoltage region extending down to 0.2 V and a large portion of theplateau region. Similar voltage profiles of other high temperaturetreated carbon materials for sodium-ion batteries have also beenreported previously. The observed charge capacity of the plateau regionfor TC1400 is 165 mAh g⁻¹, which is approximately 65% of the wholecapacity. For TC1600, the plateau capacity increases to 197 mAh g⁻¹,accounting for 71% of the total capacity. In carbon materials, thedisordered graphene layers are randomly distributed and can be modeledlike a “house of cards”. The sloping region of the potential profilecorresponds to the insertion of sodium between the turbostraticallydisordered graphene layers and the low-potential plateau region can beattributed to the insertion of the metal into the nanopores betweenrandomly stacked layers through a process analogous to adsorption. Whensodium is intercalating into graphene inter-layers continuously, theoverall potential decreases as the insertion of metal ions betweenlayers changes the potential for further insertion and turbostraticstacking between the parallel sheets gives rise to a distribution ofinsertion-site potentials. The Na chemical potential of the followingstep in the pore filling is close to that of the elemental sodium metal,which shows a voltage plateau close to 0 V. The improved performance oftire-derived carbon at higher firing temperature suggests that morenano-crystalline graphene layers are created and these randomly stackedlayers generate more voids for sodium storage at an elevatedtemperature.

A comparison of the discharge and charge curves of TC1600 at differentcycles is shown in FIG. 15. The plot shows that the capacity decreaseswith cycling. However, by comparing the discharge capacity profile, itis interesting to reveal that the sloping region is almost constantwhile the plateau region is reduced dramatically. This rapid plateauregion decay indicates the sodium adsorption-desorption in the nanoporesat the low-potential region and hence capacity fades and the Na platinginto nanopores is not fully reversible or has poor kinetic properties.

Ex-situ XRD measurements show for the pristine electrode, the (002) peakcentered at 25.7° and as sodium intercalates into the carbon electrode,the (002) peak shifts slightly to 25.5°, 25.4° and 25.1° for electrodesdischarged to and disassembled at 1.0 V, 0.8 V and 0.2 V, respectively.Such peak shifts to lower angle indicates an increase in d-values due tosodium insertion between the parallel graphene layers and an expansionof the interlayer spacing.

The discharge voltage profiles for all carbon samples at differentcurrent densities reveal that TC1400 and TC1600 have a larger portion ofthe low-voltage plateau, which is caused by pore plating of sodiummetal. This plateau rapidly disappears as the current density increases.TC1100 does not have a plateau and delivers a larger capacity at highercurrent density. These results indicate that the pore plating processwill be slower and needs more time to reach equilibrium than the sodiuminsertion into disordered graphene layers. To further improve the highrate capability, electrode materials conductivity could be improved witha surface coating process.

The long-term stability test was conducted for TC1100 in 1M NaClO₄ inpropylene carbonate (PC) as the electrolyte, as shown in FIG. 16. Goodcyclability performance proves that the materials could also work inother electrolytes, such as PC based systems, which can be operated atlower temperature than ethylene carbonate (EC) based electrolytes.TC1100 shows a capacity of 156 mAh g⁻¹ after 500 cycles at a currentdensity of 20 mA g⁻¹.

The invention provides for the use of solid-waste-tire-derived carbonsas anodes for sodium-ion batteries. When the pyrolysis temperature isincreased from 1100 to 1600° C., the capacity of the plateau below 0.2 Vincreases dramatically and this could help increase the full cell energydensity. The 1600° C. treated carbon shows a capacity of 203 mAh g⁻¹after 100 cycles. These tire-derived carbons demonstrate a low-cost,easily scalable option with good electrochemical capacity and stabilityfor sodium-ion battery anodes.

This invention can be embodied in other forms without departing from thespirit or essential attributes thereof. Reference should be made to thefollowing claims to determine the scope of the invention

We claim:
 1. A method of recovering carbon black, comprising the stepsof: providing a carbonaceous source material containing carbon black;contacting the carbonaceous source material with a sulfonation bath toproduce a sulfonated material; and, pyrolyzing the sulfonated materialat a temperature of from 1100 to 1490° C. to produce a layered carbonblack containing product comprising a glassy carbon matrix phase havingcarbon black dispersed therein, the layered carbon black containingproduct having an interlayer spacing of from 0.4 to 0.5 nm.
 2. Themethod of claim 1, wherein the sulfonation bath is an oleum bath.
 3. Themethod of claim 1, wherein the sulfonation bath comprises sulfonationagent is chlorosulfonic acid in 1,2 dichloroethane solution.
 4. Themethod of claim 1, wherein the sulfonation bath comprises between 0.1-65wt. % SO₃.
 5. The method of claim 1, wherein the sulfonation bathcomprises 2-30 wt. % SO₃.
 6. The method of claim 1, wherein thesulfonation bath has a temperature of between −20° C. to 200° C.
 7. Themethod of claim 1, wherein pyrolysis step is conducted at a temperaturethat is greater than 1200° C.
 8. The method of claim 1, whereinpyrolysis step is conducted at a temperature that is greater than 1300°C.
 9. The method of claim 1, wherein the pyrolysis step is conducted ata temperature from 1200-1400° C.
 10. The method of claim 1, whereinpyrolysis step is conducted at a temperature from 1250-1350° C.
 11. Themethod of claim 1, wherein the pyrolysis step is conducted at atemperature from 1100-1400° C.
 12. The method of claim 1, wherein theduration of the pyrolysis step is from 1 minute to 12 hours.
 13. Themethod of claim 1, further comprising the steps of reducing thecarbonaceous source material to at least one selected from the groupconsisting of powder and shredded rubber pieces prior to contacting thecarbonaceous source material with the oleum bath.
 14. The method ofclaim 13, wherein the powder and/or shredded rubber pieces has anaverage maximum dimension of less than 100 nm to 10 cm.
 15. The methodof claim 1, wherein the carbonaceous source material comprises carbonreinforced composites.
 16. The method of claim 15, wherein the carbonreinforcing agent is at least one selected from the group consisting ofcarbon black, carbon particles, nanoparticles, mesoparticles and fibers.17. The method of claim 1, wherein the carbonaceous source material is awaste material.
 18. The method of claim 17, wherein the waste materialis rubber tires.
 19. The method of claim 1, wherein the average poresize of the carbon black product is less than 8 nm.
 20. The method ofclaim 1, wherein the average pore size of the carbon black product isbetween 2 and 120 nm.
 21. The method of claim 1, wherein the isolatedcarbon is further surface activated and the density of average pore sizeof the carbon black product between 1 and 20 nm is increased.
 22. Themethod of claim 1, wherein the carbon black containing product has aspecific surface area of less than 2000 m²/g.
 23. The method of claim 1,wherein the carbon black containing product has a specific surface areaof less than 1000 m²/g.
 24. The method of claim 1, wherein the carbonblack containing product has a specific surface area of less than 100m²/g.
 25. The method of claim 1, wherein the pyrolyzing step occursafter the contacting step.
 26. The method of claim 1, wherein thepyrolyzing step occurs before the contacting step.
 27. A method ofmaking a battery electrode comprising carbon black, the methodcomprising the steps of: providing a carbonaceous source materialcontaining carbon black; contacting the carbonaceous source materialwith an oleum bath to produce a sulfonated material; pyrolyzing thesulfonated material at a temperature of from 1100 to 1490° C. to producea layered carbon black product comprising a glassy carbon matrix phasehaving carbon black dispersed therein, the layered carbon blackcontaining product having an interlayer spacing of from 4 to 5angstroms; and, forming a battery electrode from the carbon blackcontaining product.
 28. The method of claim 27, wherein the batteryelectrode is an anode.
 29. The method of claim 28, wherein the batteryis a lithium ion or a sodium ion battery.
 30. The method of claim 27,wherein the battery is a lithium ion battery or a sodium ion battery.31. The method of claim 27, wherein pyrolysis step is conducted at atemperature that is greater than 1200° C.
 32. The method of claim 27,wherein pyrolysis step is conducted at a temperature from 1200-1490° C.33. The method of claim 27, wherein the pyrolysis step is conducted at atemperature from 1200-1400° C.
 34. The method of claim 27, whereinpyrolysis step is conducted at a temperature from 1250-1350° C.
 35. Themethod of claim 27, wherein the pyrolysis step is conducted at atemperature from 1100-1400° C.
 36. A battery, comprising: an anodecomprising layered carbon black containing product obtained by providinga carbonaceous source material containing carbon black, contacting thecarbonaceous source material with an oleum bath to produce a sulfonatedmaterial, pyrolyzing the sulfonated material at a temperature of from1100 to 1490° C. to produce the layered carbon black product comprisinga glassy carbon matrix phase having carbon black dispersed therein, thelayered carbon black containing product having an interlayer spacing offrom 4 to 5 angstroms; a cathode; and, an electrolyte disposed betweenthe anode and the cathode.
 37. The battery of claim 36, wherein thebattery is a lithium battery.
 38. The battery of claim 36, wherein thebattery is a sodium battery.
 39. The battery of claim 36, wherein theaverage pore size of the carbon black containing product is less than 8nm.
 40. The battery of claim 36, wherein the average pore size of thecarbon black containing product is between 2 and 120 nm.
 41. The batteryof claim 36, wherein the isolated carbon is further surface activatedand the density of average pore size of the carbon black containingproduct between 1 and 20 nm is increased.
 42. The battery of claim 36,wherein the carbon black containing product has a specific surface areaof less than 2000 m²/g.
 43. The battery of claim 36, wherein the carbonblack containing product has a specific surface area of less than 1000m²/g.
 44. The battery of claim 36, wherein the carbon black containingproduct has a specific surface area of less than 100 m²/g.
 45. Thebattery of claim 36, wherein the layered carbon black containing producthas surface atomic composition that is greater than 92% carbon
 46. Thebattery of claim 36, wherein pyrolysis step is conducted at atemperature that is greater than 1200° C.
 47. The battery of claim 36,wherein pyrolysis step is conducted at a temperature that is greaterthan 1300° C.
 48. The battery of claim 36, wherein the pyrolysis step isconducted at a temperature from 1200-1400° C.
 49. The battery of claim36, wherein pyrolysis step is conducted at a temperature from 1250-1350°C.
 50. The battery of claim 36, wherein the pyrolysis step is conductedat a temperature from 1100-1400° C.